COMAU's implementation of its in.Grid Robot Monitoring platform at IVECO's Valladolid facility in Spain marks a significant step in enhancing the company's industrial digitalization strategy. The cloud-based system is engineered to boost operational visibility and optimize maintenance efforts by closely monitoring COMAU robots on IVECO's Door Ring and Mascherone assembly lines.
Designed to autonomously capture production and process data, COMAU’s in.Grid system detects performance variations and anomalies while verifying key performance indicators set by users. These insights allow IVECO’s engineering team to enhance robot usage, decrease unexpected downtime, and bolster overall process reliability.
Flexible Production Concept
In alignment with its holistic approach, COMAU has collaborated with IVECO in applying simultaneous engineering methods, which include the installation of both the Framing and Door production lines.
These lines incorporate a flexible production concept, utilizing COMAU’s geogripper Framing line and table-top standard Door line designs, all integrated with the company’s proprietary Versa Pallet transport system.
Enhancing Maintenance Scheduling
COMAU is actively enriching the platform's scalability through advanced artificial intelligence integration
By embedding in.Grid into its existing automation infrastructure, IVECO can now operate within a unified digital ecosystem that enhances proactive maintenance and data-driven decision-making. The comprehensive processing of robot controller data enables detailed insights into each robot's operational status, performance metrics, and maintenance requirements.
Beyond monitoring, in.Grid encompasses asset management and variable tracking, enabling IVECO to visualize historical data, track spot-welding metrics, and refine maintenance timing. Furthermore, the scalable solution supports expansion to more robots, lines, or plants while maintaining consistent data integrity and user experience. COMAU is actively enriching the platform's scalability through advanced artificial intelligence integration.
Global Production Network
Giuseppe Daresta, Head of Advanced Manufacturing Solutions & ESG at IVECO Group, expressed, “IVECO and COMAU share a long-standing partnership based on industrial excellence and innovation. As a leader in automation, COMAU has supported the evolution of our manufacturing footprint toward more digital and resilient operations.”
Daresta added that the platform is pivotal for IVECO's digital transformation, aiding in predictive maintenance and enhancing efficiency across its global production framework.
Improving Production Processes
According to Giovanni Volpes, Chief Extended Europe Officer at COMAU, digitalization is crucial for enhancing production processes.
“Our latest solution, in.Grid, provides an advanced layer of digital intelligence to the industrial setting, and we are delighted to see our technology implemented by such an innovative and longstanding partner like IVECO.” Volpes stressed that combining high-frequency monitoring with predictive analytics helps manufacturers like IVECO boost production efficiency and stabilize processes.
Proactive Performance Monitoring
The in.Grid platform offers operational benefits such as proactive performance monitoring
The in.Grid platform offers operational benefits such as proactive performance monitoring, allowing manufacturers to preemptively address potential issues. Its adaptable architecture can suit various plant sizes while ensuring cost-effectiveness through a subscription model. By enhancing process transparency, it reduces maintenance expenditures, mitigates downtime, and elevates overall production reliability, ultimately extending the robotic fleet's lifespan and efficacy.
The prosperous deployment at IVECO Valladolid underscores COMAU’s dedication to providing intelligent, connected automation solutions that facilitate measurable improvements in performance, sustainability, and operational resilience.
Light Commercial Vehicle
The IVECO plant in Valladolid, with its rich history of over 60 years, produces the Daily light commercial vehicles and the cabs of the heavy range.
Celebrating the milestone of the 700,000th unit of the Daily in 2022, the facility demonstrates ongoing success and efficiency. Recognized for its Industry 4.0 commitments and continual advancement, the plant has earned accolades for its innovative and digital transformation efforts.
COMAU has deployed its in.Grid Robot Monitoring platform at IVECO’s Valladolid plant in Spain, helping support the customer’s industrial digitalisation strategy. Developed to enhance operational visibility and improve maintenance efficiency, the cloud-based system monitors COMAU robots on IVECO’s Door Ring and Mascherone assembly lines.
COMAU’s in.Grid Robot Monitoring system autonomously captures production and process data, identifies performance deviations, signals anomalies, and verifies user-defined KPIs. This statistical and trend-based analysis helps IVECO’s engineering team optimize robot utilization, reduce unplanned downtime, and strengthen overall process reliability.
Flexible production concept
Aligned with the company’s comprehensive approach, COMAU supported the IVECO project through simultaneous engineering efforts that included installation of the Framing line and the Door line.
Not only were both lines designed with a flexible production concept, the COMAU-supplied geogripper Framing line features a ring-shaped layout engineered to minimize non-value-added stations and maximize efficiency. Similarly, for the Door line, COMAU applied its proprietary table-top standard during the development process. Both the Framing and Door lines utilize COMAU robots and its Versa Pallet transport system.
Improving maintenance scheduling
By integrating in.Grid within the existing automation infrastructure, IVECO has gained a unified digital environment that supports proactive maintenance and informed decision-making. The platform’s capacity to process large volumes of data directly from robot controllers ensures a detailed understanding of each robot’s status, performance, and maintenance needs.
Alongside its monitoring capabilities, in.Grid offers asset management and variable tracking functions, allowing IVECO to visualise historical trends, monitor spot-welding parameters, and improve maintenance scheduling. Furthermore, the intelligent and scalable solution supports future expansion across additional robots, lines, or plants while maintaining the same data integrity and user experience. In tandem, COMAU is working to enrich the advanced scalability of its robot monitoring solution through the enhanced integration of artificial intelligence.
Global production network
“IVECO and COMAU share a long-standing partnership based on industrial excellence and innovation. As a leader in automation, COMAU has supported the evolution of our manufacturing footprint toward more digital and resilient operations,” said Giuseppe Daresta, Head of Advanced Manufacturing Solutions & ESG at IVECO Group.
“The in.Grid platform is a key milestone in our digital transformation, enabling predictive maintenance, improved asset performance, and greater efficiency and sustainability across our global production network.”
Improving production processes
“Digitalisation is a key element for improving production processes. For this reason, COMAU is dedicated to driving the development of cutting-edge technologies in this area. Our latest solution, in.Grid, provides an advanced layer of digital intelligence to the industrial setting, and we are delighted to see our technology implemented by such an innovative and longstanding partner like IVECO,” emphasized Giovanni Volpes, Chief Extended Europe Officer.
“By combining high-frequency monitoring with predictive analytics, the system helps manufacturers like IVECO increase production efficiency and achieve greater process stability.”
Proactive performance monitoring
The in.Grid platform delivers clear operational advantages, including proactive performance monitoring and analytics that help manufacturers anticipate and resolve issues before they affect production. Its flexible architecture ensures adaptability across different plant sizes while maintaining cost efficiency through a subscription model. By improving process visibility, in.Grid reduces maintenance costs, minimizes downtime, and enhances overall production reliability, extending the lifespan and performance of the robotic fleet.
The successful implementation at IVECO Valladolid reflects COMAU’s commitment to delivering intelligent, connected automation solutions that empower manufacturers to achieve measurable improvements in performance, sustainability, and operational resilience.
Light commercial vehicle
The IVECO factory in Valladolid is an industrial plant with more than six decades of history where both the light commercial vehicle Daily and the cabs of the heavy range are produced, consolidating itself as a benchmark for efficiency and employment in Castilla y León. In 2022 celebrated the production of the 700,000 unit of the Daily, which reflects the continuity and success of its productive activity.
The plant has been recognized for its commitment to Industry 4.0 and continuous improvement, receiving several awards for its innovation and digital transformation.
